Electrical distribution functional module

ABSTRACT

A functional module comprises a front cover having a front side defining an electrical distribution function and a back cover having a back side defining a plurality of shielded plugs. A contact set is adapted to communicate electrical power via the shielded plugs for the electrical distribution function. The front cover and said back cover are configured to latch together so as to enclose at least a portion of the contact set.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.10/443,444 entitled Safety Module Electrical Distribution System, filedMay 22, 2003, now U.S. Pat. No. 6,884,111 which relates to and claimsthe benefit of prior U.S. Provisional Applications No. 60/383,269entitled Safety Plug-In Module Electrical Distribution System, filed May23, 2002 and No. 60/441,852 entitled Safety Module ElectricalDistribution System, filed Jan. 21, 2003. This application also relatesto and claims the benefit of prior U.S. Provisional Application No.60/649,318 entitled Dimmer Switch Module, filed Feb. 1, 2005. All of theaforementioned prior applications incorporated by reference herein.

BACKGROUND OF THE INVENTION

Standard AC electrical systems are comprised of an electrical box and anelectrical device, such as an outlet or switch, installed within thebox. During a roughing phase of construction, electrical boxes aremounted to wall studs at predetermined locations. After the boxes areinstalled, a journeyman electrician routes power cables through buildingframing to the appropriate boxes. The power cable is fed throughopenings in the rear or sides of the electrical boxes and folded backinto the boxes, unterminated, so as to be out of the way until the nextphase. During a makeup phase, wall panels are installed and painted, andthe journeyman returns to the construction site to install theelectrical devices into the boxes. After conductors are wired to anelectrical device, it and the attached conductors are pushed into theelectrical box and the device is attached to the top and bottom of thebox with screws. During a trim phase, face plates are mounted over theopen-end of the electrical boxes, completing the standard electricalwiring process.

SUMMARY OF THE INVENTION

Standard AC electrical systems are problematic in construction and use,with respect to costs, safety and functionality. From an electricalcontractor perspective, a journeyman electrician must make two separatetrips to the job site, one for the rough phase and one for the makeupphase. Also, during the makeup phase, installation of the wall panelscan damage the work completed during the rough phase. This occurs, forexample, when a router contacts exposed cables as drywallers create ahole to accommodate electrical box openings. Another form of damageoccurs when drywall compound or paint fouls the exposed cables,insulation and labeling.

From a general contractor's perspective, verification of the electricalcontractor's work is not possible until after the makeup phase. Untilthen, the electrical cables are unterminated. After the makeup phase,however, miswiring typically requires cutouts in the installed wallpanels and associated patches after corrections are completed. Further,the electrical system cannot be activated until after verification.Thus, during the rough and makeup phases, electricity for tools andlighting must be supplied by generators, which create hazards due tofumes, fuel, and noise and are an unreliable electrical source. Inaddition, until the trim phase is completed, unskilled personnel haveaccess to the electrical cable. Tampering can compromise the integrityof the electrical wiring and also create a safety problem after power isactivated.

From a homeowner's perspective, there are problems with repair of thestandard electrical wiring. Replacement of a broken outlet or switchdevice first requires removal of a face plate. The screws that attachthe module to the top and bottom of the electrical box must be removednext. The device is then removed from the box and the conductors areremoved by loosing the screws on the outlet sides. The process is thenreversed to attach the conductors to a new device and mount the newdevice into the electrical box.

The prior art electrical device replacement procedure described aboveexposes the homeowner to AC wiring upon removal of the face plate. Thisexposure creates a shock hazard. Further, a homeowner's reluctance tochange out broken devices or to spend the money to hire an electricianalso creates a shock and a fire hazard from continued use of cracked,broken or excessively worn outlets or switches. In addition, theintegrity of the original wiring becomes questionable if a homeowner orother third party removes and replaces an electrical device. Miswiringby a third party can violate building codes and create shock and firehazards, such as inadvertently switching the hot and neutral conductors,failing to attach ground wires, kinking or nicking conductors orimproperly tightening connections.

A modular electrical distribution system benefits the electricalcontractor in several respects. A wiring module is installed internallyto an electrical box and associated functional modules, such as a dimmerswitch module, are removably installed into the wiring module withoutexposure to or access to electrical system wiring attached behind thepanel. The journeyman's work can completed at the rough phase, wheninstallation of the wiring module is complete. Thus, there is no needfor the journeyman to return to the job site during the makeup phasebecause any semi-skilled laborer can insert, for example, an appropriateoutlet or switch module. Further, there is no wiring access after therough phase, protecting wiring integrity. Also, there are no exposedconductors or parts inside the electrical box that can be inadvertentlydamaged during wall panel installation.

A modular electrical distribution system also benefits the generalcontractor. Because wiring is completed during rough framing,verification and activation of the building electrical system can beperformed at the rough phase. Miswiring can be corrected before wallpanels are installed and painted, eliminating cut and patch repairs.Early electrical system activation eliminates the need to usegenerators. Lack of third party access to the journeyman's wiringpreserves integrity after verification and eliminates shock exposure toother workers.

A modular electrical distribution system also benefits the homeowner.Replacement of broken sockets and switches can be easily and safelyaccomplished. Safety is enhanced by reducing exposure to electricalwiring and encouraging replacement of defective outlets and switches.Further, maintenance costs are reduced by reducing the need to hire anelectrician for repairs. Wiring integrity is insured by reducing theopportunity of unqualified third parties to access the electricalsystem.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A–B are perspective views of an outlet module installed andremoved, respectively, from a corresponding wiring module;

FIGS. 2A–B are perspective views of a switch module installed andremoved, respectively, from a corresponding wiring module;

FIGS. 3–8 are perspective views of an outlet module and outlet modulecomponents;

FIGS. 3A–B are front and back perspective views, respectively, of anoutlet module;

FIGS. 4A–B are exploded, front perspective views of outlet modules;

FIGS. 5A–B are front and back perspective views, respectively, of anoutlet module front cover;

FIGS. 6A–B are front and back perspective views, respectively, of anoutlet module back cover;

FIGS. 7A–B are front and back perspective views, respectively, of anoutlet module power contact set;

FIGS. 8A–B are front and back perspective views, respectively, of anoutlet module ground contact set;

FIGS. 9–15 are perspective views of a switch module and switch modulecomponents;

FIGS. 9A–B are front and back perspective views, respectively, of aswitch module;

FIG. 10 is an exploded, front perspective view of a switch module;

FIGS. 11A–B are front and back perspective views, respectively, of aswitch module switch;

FIGS. 12A–B are front and back perspective views, respectively, of aswitch module front cover;

FIGS. 13A–B are front and back perspective views, respectively, of aswitch module single-pole, single throw (SPST) contact set;

FIGS. 13C–D are front and back perspective views, respectively, of aswitch module single-pole, double throw (SPDT) contact set;

FIGS. 13E–F are front and back perspective views, respectively, of aswitch module double-pole, double throw (DPDT) contact set;

FIGS. 14A–B are front and back perspective views, respectively, of aswitch module actuator;

FIGS. 15A–B are front and back perspective views, respectively, of aswitch module back cover;

FIGS. 16–22 are perspective views of a wiring module and wiring modulecomponents;

FIGS. 16A–B are front and back perspective views, respectively, of aterminal-block wiring module;

FIGS. 16C–D are back perspective views of a terminal-block wiring moduleand associated terminal guards in open positions;

FIGS. 16E–F are front and back views, respectively, of a terminal-blockwiring module and position-dependent wiring labels;

FIGS. 16G–H are switch and outlet wiring schematics, respectively;

FIG. 17A–B are exploded, front perspective views of a terminal-blockwiring module with stationary-mount and swivel-mount terminal guards,respectively;

FIGS. 18A–B are front and back perspective views and a back view,respectively, of a wiring panel;

FIGS. 19A–B are front and back perspective views, respectively, of amounting bracket;

FIGS. 20A–B are front and back perspective views, respectively, of awiring panel front cover;

FIGS. 21 is a perspective view of a wiring panel terminal set;

FIGS. 22A–B are front and back perspective views, respectively, of awiring panel back cover;

FIGS. 23A–B are front and back perspective views, respectively, of afixed-wire wiring module;

FIGS. 24A–B are exploded, front and back perspective views,respectively, of a fixed-wire wiring module;

FIGS. 25A–B are front and back perspective views, respectively, of anelectrical box cover;

FIGS. 26A–B are front perspective views of a covered and uncoveredelectrical box, respectively;

FIG. 27 is a front perspective view of a 2-gang electrical box withoverlapping covers;

FIGS. 28A–B are back perspective and back perspective exploded views,respectively, of a wiring module having a terminal shield;

FIGS. 29A–B are front and back perspective views, respectively, of aterminal shield;

FIGS. 30A–B are front and back perspective views, respectively, of adimmer switch module;

FIG. 31 is an exploded, front perspective view of a dimmer switchmodule;

FIGS. 32A–B are front and back perspective views, respectively, of apower control;

FIGS. 33A–B are front and back perspective views, respectively, of afront cover;

FIGS. 34A–B are front and back perspective views, respectively, of aspring;

FIGS. 35A–B are front and back perspective views, respectively, of adimmer control;

FIGS. 36A–B are front and back perspective views, respectively, of aheat sink;

FIGS. 37A–C are front perspective, back perspective and front views,respectively, of dimmer circuit board;

FIGS. 38A–B are front and back perspective views, respectively, of aback cover; and

FIG. 39 is a schematic diagram of a dimmer circuit.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

System Overview

FIGS. 1–2 illustrate a safety module electrical distribution system 100having a functional module 110 and a wiring module 1600. The electricaldistribution system 100 is configured to mount within a standardelectrical box (not shown), such as is typically installed within abuilding wall. In particular, the wiring module 1600 is configured to beeasily installed within an electrical box, and a functional module 110is configured to be removably plugged into the wiring module 1600, asdescribed below. FIGS. 1A–B show an outlet module 300 in an installedand a removed position, respectively. FIGS. 2A–B show a switch module900 in an installed and a removed position, respectively. A face plate(not shown) may be installed over a functional module 110 so as toprovide an aesthetic trim.

As shown in FIGS. 1–2, each functional module 110 provides auser-accessible electrical distribution function. As shown in FIGS.1A–B, the functional module 110 may be an outlet module 300, whichfunctions to supply a user with electrical power through a conventionalAC plug inserted into one of the module sockets. The outlet module 300is configured for installation in a ground-up position in a wiringmodule 1600 oriented for outlet installation. Alternatively, an outletmodule and wiring module can be configured for outlet installation in aground-down position.

As shown in FIGS. 2A–B, the functional module 110 may be a switch module900, which allows a user to control electrical power to an outlet, alight or any of various electrical devices (not shown) by actuating themodule switch. The switch is slideable between first and secondpositions in contrast to a conventional toggle switch, such as used forturning an interior light on and off. The switch module 900 isconfigured for installation in a wiring module 1600 oriented for switchinstallation. Reversible wiring module 1600 orientation within anelectrical box to indicate the module to be installed and its properorientation is described in detail with respect to FIGS. 16A–H, below

Other outlet and switch related functional modules 110 may include GFCIoutlets, covered safety outlets and dimmer switches (FIGS. 23–24) toname just a few. Further, the electrical distribution system 100 may bewall-mounted, ceiling-mounted or floor-mounted. In additional, theelectrical distribution system 100 can be adapted for uses other thanbuilding electrical distribution, such as airplane, automobile or boatelectrical distribution applications, to name a few. A modularelectrical outlet and switch system is described in U.S. Pat. No.6,341,981 entitled Safety Electrical Outlet and Switch System, and acovered safety outlet module and corresponding plug are described inU.S. patent application Ser. No. 10/737,713 entitled Safety Plug andCovered Outlet Module, both assigned to ProtectConnect, Irvine, Calif.and incorporated by reference herein.

Outlet Module

FIGS. 3A–B illustrate an outlet module 300 having a body 310, a frontside 301 and a back side 302. The body 310 accepts attachment screws 305on diagonally opposite corners that are utilized to secure the outletmodule 300 to a wiring module 1600 (FIGS. 1A–B). The outlet module frontside 301 provides upper and lower sockets 320 each configured to accepta conventional, three-wire (grounded) electrical plug. The outlet moduleback side 302 provides shielded plugs 330 and a ground bar 834 thatphysically and electrically connect the outlet module 300 to a wiringmodule 1600 (FIGS. 1A–B). The shielded plugs 330 transfer electricalpower to the sockets 320, and the ground bar 834 provides a ground pathfor the sockets 320. The ground bar 834 also functions as a key toassist in orienting the outlet module 300 relative to the wiring module1600 (FIGS. 1A–B).

FIG. 4A illustrates an outlet module 300 having a front cover 500, arear cover 600, a power contact set 700 and a ground contact set 800.The front cover 500 and back cover 600 form the outlet module body 310(FIGS. 3A–B). The covers 500, 600 advantageously snap together with alatch and catch assembly, described with respect to FIGS. 5–6, below.This reduces manufacturing assembly steps and reduces or eliminates theneed for separate fasteners, such as rivets or screws and/or sonicwelding. The contact set 700, 800 is retained within the covers 500, 600and provides conductive paths from the wiring panel 1600 (FIGS. 16A–B)to the outlet sockets 320 (FIG. 3A). In particular, a power contact set700 transfers power from the shielded plugs 330 (FIG. 3B) to the outletsockets 320 (FIG. 3A). A ground contact set 800 provides a ground pathbetween a ground bar 834 (FIG. 3B) and the outlet sockets 320 (FIG. 3A).The ground contact set components 810, 830, 850 are assembled asdescribed with respect to FIGS. 8A–B, below. In one embodiment, thecovers 500, 600 are constructed of nylon. FIG. 4B illustrates analternative embodiment of an outlet module 400, such as for 20Aapplications

FIGS. 5A–B illustrate the outlet module front cover 500 having anoutside face 501, an inside face 502, outlet apertures 510, attachmentears 520, side latches 530 and contact housing structure 540, 550. Asshown in FIG. 5A on the outside face 501, the outlet apertures 510 formthe entry to the outlet module sockets 320 (FIG. 3A) and include a hotslot, neutral slot and ground hole for each of a top socket and bottomsocket. The attachment ears 520 are advantageously integral to the frontcover 500, eliminating the need for a separate mechanism for attachingthe outlet module 300 (FIGS. 3A–B) to the wiring module 1600 (FIGS.16A–B). The attachment ears 520 are located at an upper right corner anda diagonally opposite lower left corner (not visible), and each has afastening aperture that accepts, for example, an attachment screw 305(FIGS. 3A–B). The side latches 530 form the front cover portion of thelatch and catch assembly, functionally described with respect to FIG. 4,above.

As shown in FIG. 5B on the inside face 502, a power contact structure540 accepts the power contact set 700 (FIGS. 7A–B) so that the powercontact clips 701 (FIGS. 7A–B) align with the hot and neutral slots ofthe outlet apertures 510. A ground contact structure 550 accepts theground contact set 800 (FIGS. 8A–B) so that the ground contact clips832, 852 (FIGS. 8A–B) align with the ground holes of the outletapertures 510.

FIGS. 6A–B illustrate the outlet module back cover 600 having an outsideface 601, an inside face 602, plug shields 610, a ground bar aperture620, side catches 630 and contact support structure 640, 650. As shownin FIG. 6B on the outside face 601, the plug shields 610 advantageouslyprovide the shield portion of the shielded plugs 330 (FIG. 3B).Specifically, the plug shields 610 completely surround all sides of thepower contact set prongs 702 (FIGS. 7A–B). In this manner, the prongs702 (FIGS. 7A–B) are not exposed when the outlet module plugs 330 (FIG.3B) are engaged with the wiring module sockets 810 (FIG. 18A), even whenthe outlet module 300 (FIGS. 3A–B) is partially separated from thewiring module 1600 (FIGS. 16A–B). The ground bar aperture 620 allows theground bar 834 (FIGS. 8A–B) to protrude through the back cover 600,providing a ground contact with the wiring module 1600 (FIGS. 16A–B).The side catches 630 provide apertures that accept and engage the sidelatches 530 (FIGS. 5A–B) so as to releaseably secure together the frontcover 500 (FIGS. 5A–B) and the back cover 600.

As shown in FIG. 6A on the inside face 602, a power contact supportstructure 640 consists of slots that allow the prongs 702 (FIGS. 7A–B)to protrude through the back cover 600 within the plug shields 610,providing a power connection with the wiring module 1600 (FIGS. 16A–B).A ground contact support structure 650 supports the ground contact set800 (FIGS. 8A–B).

FIGS. 7A–B illustrate the power contact set 700 having an upper hotcontact 710, a lower hot contact 720, an upper neutral contact 730 and alower neutral contact 740. Each contact 710–740 has a prong clip 701interconnected with a prong 702. The prong clips 701 align with thefront cover hot and neutral slots 510 (FIG. 5A) to form the outletmodule sockets 320 (FIG. 3A). The prongs 702 insert through the powercontact support structure 640 into the plug shields 610 to form theoutlet module shielded plugs 330 (FIG. 3B). Advantageously, the powercontact set 700 is configured so that the contacts may be manufacturedby a stamp and fold process. In one embodiment, the contacts are brass.

FIGS. 8A–B illustrate a ground contact set 800 having a ground buss 810,an upper ground contact 830 and a lower ground contact 850. The groundclips 832, 852 align with the front cover ground holes 510 (FIG. 5A) toform the ground portion of the outlet module sockets 320 (FIG. 3A). Theground bar 834 protrudes through the back cover 600 (FIGS. 6A–B) toprovide a ground path connection with the wiring module 1600 (FIGS.16A–B). The unassembled ground contact set 800 is illustrated in FIG. 4,above. Ground contact set 800 assembly is described below.

As shown in FIGS. 8A–B, the ground buss 810 has a upper rivet 812, alower rivet 814, a upper cutout 815, a slot 816 and a lower cutout 818.The ground buss 810 mechanically supports and electrically interconnectsthe upper ground contact 830 and the lower ground contact 850. The upperground contact 830 has an upper ground clip 832, a ground bar 834,leaves 836 and a tab 838. The upper ground clip 832 and ground bar 834extend from opposite ends of the upper ground contact 830. The upperground clip 832 accepts a ground pin from a standard AC electrical plug.The ground bar 834 inserts into a corresponding ground clip 1902 (FIGS.19A–B) in the wiring module 1600 (FIGS. 16A–B). The tab 838 extendsgenerally perpendicularly below and between the clip 832 and bar 834 andhas an aperture corresponding to the top rivet 812. The leaves 836extend from the back of the clip 832. The lower ground contact 850 has alower ground clip 852, leaves 854 and a tab 858. The tab 858 extendsgenerally perpendicularly to the clip 852 and has an aperturecorresponding to the lower rivet 814. The leaves 854 extend from theback of the clip 852.

Also shown in FIGS. 8A–B, the ground contact set 800 is assembled byinserting the upper ground contact 830 and lower ground contact 850 intothe ground buss 810. Specifically, the ground bar 834 is inserted intothe slot 816, the leaves 836, 854 are inserted into the upper and lowercutouts 815, 818, respectively, the upper and lower rivets 812, 814 areinserted through the tabs 838, 858. The rivets 812, 814 are thensplayed, fixedly attaching the upper and lower ground contacts 830, 850to the ground buss 810. Advantageously, the ground contact set 800 isconfigured so that the ground contact set components 810, 830, 850 maybe manufactured by a stamp and fold process. In one embodiment, theupper and lower ground contacts 830, 850 are brass and the ground buss810 is zinc-plated steel.

Switch Module

FIGS. 9A–B illustrate a switch module 900 having a body 910, a frontside 901 and a back side 902. Like the outlet module body 310 (FIGS.3A–B), the switch module body 910 accepts screws on diagonally oppositecorners that are utilized to secure the switch module 900 to a wiringmodule 1600 (FIGS. 2A–B). The switch module front side 901 has aslideable switch 1100 configured to actuate internal contacts so as toroute electrical power, to turn on and off a light, for example. Likethe outlet module 300 (FIGS. 3A–B), the switch module back side 902provides shielded plugs 930 that physically and electrically connect theswitch module 900 to a wiring module 1600 (FIGS. 2A–B). The shieldedplugs 930 conduct electrical power under control of the switch 1100.There may be null plugs 940 having no conductors depending on the switchmodule 900 configuration and associated function, as described withrespect to FIGS. 13A–F, below. The switch module 900 does not require aground path to the wiring module 1600 (FIGS. 2A–B). A key bar 1520,therefore, provides a non-conducting structure that substitutes for aground bar 834 (FIG. 3B), to assist in orienting the switch module 900relative to the wiring module 1600 (FIGS. 2A–B).

FIG. 10 illustrates a switch module 900 having a switch 1100, a frontcover 1200, a rear cover 1500, a contact set 1300, an actuator 1400 anda spring 1000. The front cover 1200 and back cover 1500 form the switchmodule body 910 (FIGS. 9A–B). The covers 1200, 1500 advantageously snaptogether and are secured with a latch and catch assembly, described withrespect to FIGS. 12A–B and 15A–B, below. This reduces manufacturingassembly steps and reduces or eliminates the need for separatefasteners, such as rivets or screws and/or sonic welding. In oneembodiment, the covers 1200, 1500 are constructed of nylon.

As shown in FIG. 10, the switch 1100 snaps into and is slidably retainedby the front cover 1200 and engages the actuator 1400. The switch 1100is movable between a first position and a second position. The contactset 1300, actuator 1400 and spring 1000 are retained within the covers1200, 1500. The contact set 1300 routes electrical power from the wiringpanel 1600 (FIGS. 1A–B) as determined by the switch 1100 positions. Inparticular, the position of the switch 1100 determines the position ofthe actuator 1400, which, in turn, determines whether the contact set1300 is open or closed. If closed, the contact set 1300 provides aconductive path that transfers power between the shielded plugs 930(FIG. 3B). The switch 1100 remains in its manually set position undertension from the spring 1000.

FIGS. 11A–B illustrate a switch 1100 that is generally rectangular,having a front side 1101 and a back side 1102. The front side 1101 has afinger grip 1110 for manually sliding the switch between its firstposition and its second position, as described above. The back side 1102has latches 1120 and a lever 1130 that extends in a direction generallynormal to the plane of the back side 1102. The latches 1120 areconfigured to pass through front cover slots 1214 (FIG. 12A), whichcause the latches 1120 to flex inward toward the extension 1130 as theswitch 1100 is pressed into the front cover 1200 (FIGS. 12A–B). Thelatches 1120 spring outward after the latches pass through the slots1214 (FIG. 12A), seating the switch in the front cover 1200 (FIGS.12A–B), as described below. The lever tip 1132 inserts through theactuator slot 1410 (FIGS. 14A–B) and contacts the spring 1000,mechanically connecting the switch 1100 to the actuator 1400 (FIGS.14A–B).

FIGS. 12A–B illustrate a front cover 1200 having an outside face 1201,an inside face 1202, a switch cavity 1210, attachment ears 1220, sidelatches 1230 and top and bottom catches 1240. Located on the outsideface 1201, the cavity 1210 is configured to accommodate the switch 1100(FIGS. 11A–B). Within the cavity 1210 is a lever slot 1212 that allowsthe switch lever 1130 (FIG. 11B) to pass through the front cover to theactuator 1400 (FIGS. 14A–B). The lever slot 1212 extends along thecavity 1210 a sufficient distance to allow switch movement between firstand second positions, as described above. Also within the cavity 1210are catch slots 1214 that accommodate and capture the switch latches1120 (FIG. 11B), as described above. The attachment ears 1220 arelocated at an upper right corner and a diagonally opposite lower leftcorner (not visible), and each has a fastening aperture that accepts,for example, an attachment screw 305 (FIGS. 3A–B). The side latches 1230and top and bottom catches 1240 form the front cover portion of thelatch and catch assembly, functionally described with respect to FIG.10, above.

FIGS. 13A–B illustrate a SPST contact set 1300 having a throw buss 1310and a pole buss 1320. The throw buss 1310 has a first prong 1312, aflexible throw 1314 and a throw contact 1318. The pole buss 1320 has asecond prong 1322, a fixed pole 1324 and a pole contact 1328. The firstand second prongs 1312, 1322 form the conductive portion of the shieldedplugs 930 (FIG. 9B). The flexible throw 1314 engages the actuator 1400,as described with respect to FIGS. 14A–B, below, which moves the throwbetween an open position and a closed position (shown). In the closedposition, the throw contact 1318 touches and electrically connects withthe pole contact 1328, establishing a conductive path between the firstand second prongs 1312, 1322. In the open position, the throw contact1318 is separated from the pole contact 1328 so that there is noconductive path between the first and second prongs 1312, 1322.

FIGS. 13C–D illustrate a SPDT contact set 1301 for a 3-way switch havinga second pole buss 1330 in addition to the SPST contact set 1300 (FIGS.13A–B). The second pole buss 1330 has a third prong 1332 and a secondpole contact 1338. The flexible throw 1314 engages the actuator 1400, asdescribed with respect to FIGS. 14A–B, below, which moves the throwbetween a first position (shown) and a second position. In a firstposition, the throw contact 1318 touches and electrically connects withthe pole contact 1328, establishing a conductive path between the firstand second prongs 1312, 1322. In a second position, the throw contact1318 touches and electrically connects with the second pole contact1338, establishing a conductive path between the first and third prongs1312, 1332.

FIGS. 13E–F illustrate a DPDT contact set 1302 for a 4-way switch havinga second throw buss 1340 and a third pole buss 1350 in addition to theSPDT contact set 1301. The second throw buss 1340 has a second flexiblethrow 1344. The second throw buss 1340 has a fourth prong 1342, a secondflexible throw 1344 and a second throw contact 1348. The second polebuss 1330 has the third pole contact 1339, and the third pole buss 1350has a fourth pole contact 1359. In a first position, the throw contact1318 touches and electrically connects with the pole contact 1328,establishing a conductive path between the first and second prongs 1312,1322. Also, the second throw contact 1348 touches and electricallyconnects with the third pole contact 1339, establishing a conductivepath between the third and fourth prongs 1332, 1342. In a secondposition, the throw contact 1318 touches and electrically connects withthe second pole contact 1338, establishing a conductive path between thefirst and third prongs 1312, 1332. Also, the second throw contact 1348touches and electrically connects with the fourth pole contact 1339,establishing a conductive path between the second and fourth prongs1322, 1342.

FIGS. 14A–B illustrate an actuator 1400 having a front face 1401, a backface 1402 and a lever slot 1410 generally centered within and passingthrough the front and back faces 1401, 1402. The actuator 1400 ispositioned within the switch module 900 (FIG. 10) so that the front face1401 is proximate the front cover 1200 (FIG. 10) and the contact set1300 (FIG. 10) and the back face 1402 is proximate the spring 1000 (FIG.10) and the back cover 1500 (FIG. 10). The lever slot 1410 accommodatesthe switch lever tip 1132 (FIG. 11B), as described above. The front face1401 has a pair of upper arms 1420 and a pair of lower arms 1430extending generally perpendicularly from the front face 1401 so as toengage the contact set 1300 (FIGS. 13A–B). In particular, the flexiblethrow 1314 (FIGS. 13A–B) is engaged between the upper arms 1420. For aDPDT contact set 1302 (FIGS. 13E–F), a second flexible throw 1344 (FIGS.13E–F) is engaged between the lower arms 1430. The back face 1402 has apair of posts 1440 that are slidably retained within back cover guides1550 (FIG. 15A).

FIGS. 15A–B illustrate a rear cover 1500 having an inside face 1502, anoutside face 1501, plug shields 1510, a key bar 1520, side catches 1530,top and bottom latches 1540, actuator guides 1550, a spring hold 1560and contact support structure 1570. As shown in FIG. 15B on the outsideface 1501, the plug shields 1510 advantageously provide the shieldportion of the shielded plugs 930 (FIG. 9B). Specifically, the plugshields 1510 completely surround all sides of the contact set prongs1312, 1322 (FIGS. 13A–B). In this manner, the prongs are not exposedwhen the switch module plugs 930 (FIG. 9B) are engaged with the wiringmodule sockets 1810 (FIG. 18A), even when the switch module 900 (FIGS.9A–B) is partially separated from the wiring module 1600 (FIGS. 16A–B).The key bar 1520 is configured to insert into the wiring module groundsocket 1820 (FIG. 18A), although the key bar 1520 is nonconductive. Thekey bar 1520 assists proper orientation of the switch module 900 (FIGS.9A–B) to the wiring module 1600 (FIGS. 16A–B). The side catches 1530provide apertures that accept and engage the side latches 1230 (FIGS.12A–B), and the top and bottom latches 1540 insert into and engage thetop and bottom catches 1240 (FIGS. 12A–B) so as to releaseably securetogether the front cover 1200 (FIGS. 12A–B) and the back cover 1500.

As shown in FIG. 15A on the inside face 1502, the actuator guides 1550slidably retain the actuator posts 1440 (FIG. 14B). The spring hold 1560accommodates and retains the spring 1000 (FIG. 10). The contact supportstructure 1570 consists of slots through the back cover 1500 andstructure extending generally normal to the inside face 1502 thatsupport the contact set 1300 (FIGS. 13A–B). The slots accept the contactset prongs 1312, 1322 (FIGS. 13A–B), which protrude through the backcover 1500 within the plug shields 1510.

Terminal-Block Wiring Module

FIGS. 16A–B illustrate a terminal-block wiring module 1600 having afunctional side 1601 and a wiring side 1602. The functional side 1601has structured sockets 1810 and an off-center ground socket 1820. Thestructured sockets 1810 accept corresponding functional module shieldedplugs, as described with respect to FIG. 20A, below. The wiring module1600 is configured to mount within a conventional electrical box (notshown), secured with attachment screws 1605. A functional module, suchas an outlet module 300 (FIGS. 3A–B) or a switch module 900 (FIGS. 9A–B)plug into the wiring module functional side 1601, secured to the wiringmodule with attachment screws that thread through attachment ears andcorresponding module mounts 1930, as described with respect to FIGS.1–2, above. A power cable (not shown) routed into the electrical boxattaches to a terminal block 1640 (FIG. 16F) accessible from the wiringmodule wiring side 1602, as described with respect to FIGS. 16E–H,below.

As shown in FIGS. 16A–B, a wiring module 1600 advantageously can beinstalled, wired and tested by journeyman electrician at the rough-inphase of building construction. The wiring module 1600 is mounted withinan electrical box according to the type of functional module for whichthe wiring module 1600 will be wired. If the wiring module 1600 ismounted in a first orientation (FIG. 1B), the ground socket 1820 ispositioned below-center. If the wiring module is mounted in a secondorientation (FIGS. 2B, 16A), the ground socket 1820 is positionedabove-center. The ground socket 1820 accepts an outlet module ground bar834 (FIG. 3B) or switch module key bar 1520 (FIG. 9B), which act askeys. Correspondingly, the ground socket 1820 acts as a block thataccepts a functional module key 834 (FIG. 3B), 1520 (FIG. 9B) only whenthe functional module is properly oriented with respect to the wiringmodule 1600 according to module type, such as a switch or outlet. In oneembodiment, the wiring module 1600 is mounted with the ground socket1820 above-center for a switch module 900 (FIGS. 9A–B) and mounted withthe ground socket 1820 below-center for an outlet module 300 (FIGS.3A–B), as described in further detail with respect to FIGS. 16E–H,below.

FIGS. 16C–D illustrate a terminal-block wiring module 1600 havingterminal guards 1700 that advantageously provide covered access to theterminal set 2100 (FIG. 21). In particular, in a closed position (FIGS.16A–B) the terminal guards 1700 protect users from shock and insulatebetween closely mounted high voltage devices. In an open position (FIGS.16C–D), the terminal guards 1700 allow convenient access to the terminalscrews 2140 so as to attach or remove power cable wires from theterminal blocks 1640. As shown in FIG. 16C, a hinge 1702 allows aterminal guard 1700 to move from a closed position FIGS. (16A–B) to anopen position. A latch 1704 presses into a corresponding catch slot2220, which retains a terminal guard 1700 in a closed position until itis manually opened. As shown in FIG. 16D, in one embodiment a swivelmount 1709 (FIG. 17B) also allows the terminal guard 1700 to swivel fromside to side in an open position, further easing access to the terminalscrews 2140.

FIGS. 16E–F illustrate orientation-dependent labels on the wiring modulefunctional and wiring sides, respectively. As described above, the typeof functional module to be mounted in the wiring module 1600 determinesthe mounted orientation of the wiring module 1600 within an electricalbox. Color coded labels 1620, 1630 on the functional side (FIG. 16E) andwiring labels 1650, 1660 on the wiring side (FIG. 16F) advantageouslyindicate to the journeyman electrician the correct wiring module 1600orientation. The color coded labels 1620, 1630 also advantageouslyindicate the correct functional module to be installed or replaced. Inparticular, as shown in FIG. 16E, the color coded labels include aswitch label 1620 and an outlet label 1630. The switch label 1620 has anorientation indicator 1622 and corresponding text that specify thewiring module orientation for a switch module 900 (FIGS. 2A–B). Inaddition, color boxes 1624 advantageously match color indicators 2310(FIG. 23A) on corresponding switch modules 900. Further, as shown inFIG. 16F, the outlet label 1630 has an orientation indicator 1632 andcorresponding text that specify the wiring module orientation for anoutlet module 300 (FIGS. 1A–B). Also, color boxes 1634 match an outletcolor indicator. In one embodiment, the switch color boxes 1624 areyellow, red and orange matching SP, 3-way and 4-way switch colorindicators, respectively. The outlet color boxes 1634 are dark and lightblue for full hot and half-hot wiring, matching a blue color indicatorfor an outlet module. The color boxes 1624, 1634 are marked by thejourneyman electrician at wiring module installation to visuallyindicate the module type for which the wiring module 1600 was wired.

As shown in FIG. 16F, there are four terminal blocks 1640, each havingterminal labels “1,” “2,” “3” and “4” 1670 identifying the individualterminal blocks T1, T2, T3 and T4 by number. In a switch orientation(shown), switch labels 1650 are advantageously positioned in a mannervisually corresponding to each of the individual terminal blocks 1640.The switch labels 1650 identify switch wiring for each terminal block byswitch type SP, 3-way and 4-way. The outlet labels 1660 are upside downin the switch orientation, visually indicating that they areinapplicable. In an outlet orientation (upside down from that shown),outlet labels 1660 are similarly positioned in a manner visuallycorresponding to each of the individual terminal blocks 1640. The outletlabels 1660 identify outlet wiring. The switch labels 1650 are upsidedown in the outlet orientation, visually indicating that they areinapplicable.

FIGS. 16G–H illustrate switch and outlet wiring schematics,respectively, corresponding to the terminal labels 1670 (FIG. 16F),switch labels 1650 (FIG. 16F) and outlet labels 1660 (FIG. 16F)described with respect to FIG. 16F, above. Graphically depicted aregroups of four terminals 1690 representing the terminal blocks 1640(FIG. 16F). Also depicted are individual terminal blocks 1691,corresponding hot, neutral, traveler and switch wires 1692, and linksand gaps 1693 corresponding to removable breakaways 2116.

FIGS. 17A–B illustrate a terminal-block wiring module 1600 having awiring panel 1800 and a mounting bracket 1900. The wiring panel 1800 hasa front cover 2000, a back cover 2200, a terminal set 2100 and terminalguards 1700. The front cover 2000 and back cover 2200 are securedtogether with a fastener (not shown). The mounting bracket 1900 furthersecures the front cover 2000 to the back cover, as described withrespect to FIGS. 18–20, below. The terminal set 2100 is retained withinthe wiring panel 1800 and provides terminal blocks 1640 (FIG. 16F) forpower cable attachment and provides conductive paths between theterminal blocks 1640 (FIG. 16F) and structured sockets 1810 (FIG. 18A).The mounting bracket 1900 advantageously performs multiple functionsincluding securing the wiring module 1600 to an electrical box (notshown), securing together the front and back covers 2000, 2200,providing a ground bar clip 1902 (FIG. 19A) for contact with a moduleground bar 834 (FIG. 3B) and providing a ground terminal 1907 (FIG. 19A)for a ground wire connection.

As shown in FIGS. 17A–B, the terminal guards 1700 each have a hinge1702, a latch 1704, a mount 1706, 1709 and a grip 1708. The mount 1706,1709 slides into a corresponding guard slot 2210 (FIG. 22A) on each sideof the back cover 2200, which secures each terminal guard 1700 to thewiring panel 1800. The hinge 1702 advantageously allows a terminal guard1700 to move between a closed position (FIGS. 16A–B) blockinginadvertent contact with the terminal blocks 1640 (FIG. 16F) and an openposition (FIGS. 16C–D) allowing access to the terminal blocks 1640 (FIG.16F). The latch 1704 presses into a corresponding catch slot 2220 (FIG.22A) on each side of the back cover 2200, which retains each terminalguard 1700 in a closed position until it is manually opened. A grip 1708assists in latching the terminal guards 1700. A stationary mount 1706(FIG. 17A) holds the terminal guards 1700 in alignment with the terminalscrews 2140 (FIG. 21). Alternatively, a swivel mount 1709 (FIGS. 17B)advantageously allows the terminal guards 1700 to swivel to either side1601, 1602 (FIGS. 16A–B) of the wiring module for easier access to theterminal screws 2140 (FIG. 21).

FIGS. 18A–B illustrate a wiring panel 1800 having a front side 1801 anda back side 1802. The front side 1801 has structured sockets 1810, aground socket 1820 and bracket slots 1830. The back side 1802 hasterminal blocks 1640 (FIG. 16F) formed by a terminal set 2100 (FIG. 21)having terminal screws 2140 (FIG. 21) that are accessed through theterminal guards 1700, as described above.

FIGS. 19A–B illustrate a mounting bracket 1900 having a bracket body1901, a ground clip 1902 and a ground terminal 1907. The ground clip1902 is attached to the bracket body 1901 with a rivet 1905. The groundterminal 1907 provides a ground termination for a ground wire (notshown). The bracket 1900 has swages 1910, box mounts 1920 and modulemounts 1930. The bracket 1900 is configured to be disposed around therear cover 2200 (FIGS. 22A–B) with the swages 1910 inserted throughfront cover slots 2020 (FIGS. 20A–B) and spread against the front coveroutside 2001 so as to secure together the front and rear covers 2000,2200. A fastener 1909 is inserted through the bracket and into thewiring panel front cover 2000, so as to secure together the front andrear covers 2000, 2200. The box mounts 1920 allow the wiring module 1600(FIGS. 16A–B) to be secured to an electrical box (not shown) and areconfigured to removably engage a box cover (FIGS. 27–29). The modulemounts 1930 allow functional modules 300 (FIGS. 3A–B), 900 (FIGS. 9A–B)to be secured to the wiring module 1600 (FIGS. 16A–B). The ground clip1902 is configured to physically and electrically connect to a moduleground bar 834 (FIGS. 8A–B).

In an alternative embodiment, the mounting bracket 1900 does not haveswages 1910. Multiple fasteners 1909 are inserted through the mountingbracket 1900 and into the wiring panel front cover 2000, so as to securetogether the front and rear covers 2000, 2200. After the mountingbracket 1900 is attached to the front cover 2000, ears at the top andbottom of the mounting bracket 1900 are bent over and against the frontcover outside 2001 to further secure together the front and rear covers2000, 2200. Trusses are included across or proximate to folded portionsof the mounting bracket 1900 to strengthen the bracket structure. Thebox mount 1920 may have an alternative shape so as to accommodate a boxcover 2700 (FIGS. 27A–B).

FIGS. 20A–B illustrate a front cover 2000 having an outside face 2001and an inside face 2002. As shown in FIG. 20A on the outside face 2001,raised guards 2010 and surrounding channels 2014 provide thenonconductive portions of structured sockets 1810 (FIG. 18A). Eachraised guard 2010 and surrounding channel 2014 are configured to matewith a corresponding plug shield 610 (FIG. 6B). In particular, when afunctional module is plugged into the wiring module 1600 (FIGS. 16A–B),shields 610 (FIG. 6B), 1510 (FIG. 15B) insert into channels 2014, guards2010 insert within shields 610 (FIG. 6B), 1510 (FIG. 15B), and prongs702 (FIGS. 7A–B) plug into power clips 2112 (FIG. 21). This interlockingaction of the shield plugs 330 (FIG. 3B), 930 (FIG. 9B) and thestructured sockets 1810 (FIG. 18A) advantageously provides a fullyenclosed shield as an electrical connection is made between a functionalmodule and a wiring module, in addition to tactile feedback and a solidmechanical and electrical connection. Further, the guards 2010 andchannels 2014 reduce the chance of an inadvertent contact between atool, such as a screwdriver tip, and a hot contact within a socket 1810(FIG. 18A). For example, a tool dragged across the wiring panel frontside 1801 (FIG. 18A) during service will tend to lodge in the channel2014 or against the raised guard 2010 or both. In a particularembodiment, the shields 610 (FIG. 6B), 1510 (FIG. 15B) and thecorresponding channels 2014 and raised guards 2010 are generallyrectangular in shape with rounded corners.

As shown in FIG. 20B, the inside face 2002 has swage slots 2020, aground aperture 2030 and terminal support structure 2050, 2060. Theswage slots 2020 accommodate the mounting bracket swages 1910 (FIG.19A), which assist to secure together the front and back covers 2000,2200. The ground aperture 2030 accommodates a ground bar 834 (FIG. 3B)or key bar 1520 (FIG. 9B) as part of a ground socket 1820 (FIG. 18A).The support structure 2050, 2060 houses the terminal set 2100 (FIGS.21).

FIG. 21 illustrates a terminal set 2100 having contact busses 2110,terminal clamps 2130 and terminal screws 2140. The contact busses 2110each have power clips 2112 that provide the conductor portion of thestructured sockets 1810 (FIG. 18A). The power clips 2112 are configuredto physically and electrically connect with module prongs 702 (FIGS.7A–B), 1312, 1322 (FIGS. 13A–B). The terminal clamps 2130 and terminalscrews 2140 terminate power cables (not shown) to the contact busses2110. The terminal clamps 2130 are configured to secure one wire perchannel 2132. Advantageously, this provides a four-wire capacity foreach of four terminal blocks 1640 (FIG. 16F). In one embodiment, eachterminal block 1640 (FIG. 16F) is configured for four 14 gauge copperwires or two 12 gauge copper wires. Breakaways 2116 are removable toselectively isolate individual terminal blocks 1640 (FIG. 16F).

FIGS. 22A–B illustrate a back cover 2200 having an inside face 2202 andan outside face 2201. The inside face 2202 has mount slots 2210 andcatch slots 2220 that retain the terminal guards 1700 (FIG. 17), asdescribed above. The inside face 2202 also has terminal slots 2230 thatretain the terminal set. The outside face 2201 is shaped to accommodatethe mounting bracket 1900 (FIGS. 19A–B) and accommodate power cableattachment to the terminal blocks 1640 (FIG. 16F).

Fixed-Wire Wiring Module

FIGS. 23A–B illustrate a fixed-wire wiring module 2300 having afunctional side 2301 and a wiring side 2302. The wiring module 2300 isconfigured to mount within a conventional electrical box (not shown),secured with attachment screws (not shown) threaded through box mounts2452. A functional module, such as an outlet module 300 (FIGS. 3A–B) ora switch module 900 (FIGS. 9A–B) plug into the wiring module functionalside 2301, secured to the wiring module 2300 with attachment screws (notshown) that thread through attachment ears (not shown) and correspondingmodule mounts 2454, as described with respect to FIGS. 1–2, above. Apower cable (not shown) routed to the electrical box attaches topushwire connectors 2370 at the end of fixed wires 2350 extending fromthe wiring module wiring side 2302.

FIGS. 24A–B illustrate a fixed-wire wiring module 2300 having a frontcover 2410, a back cover 2420, a terminal set 2430, a mounting bracket2450, a ground bar clip 2460 and fasteners 2470. The front cover 2410and back cover 2420 are secured together with the fasteners 2470 andenclose the terminal set 2432. Advantageously, the mounting bracket 2450is partially enclosed by, and retained between, the front cover 2410 andback cover 2420 so as to secure the mounting bracket 2450 to, andmechanically and electrically integrate the mounting bracket with, thewiring module 2300.

As shown in FIGS. 24A–B the front cover 2410 has structured sockets2412, a ground aperture 2414, support structure 2416 and fastener posts2418. The structured sockets 2412 interlock with functional moduleshielded plugs and the ground aperture 2414 accommodates a ground bar orkey bar as part of a ground socket in a manner as described with respectto FIGS. 20A–B, above. The support structure 2416 houses the terminalset 2430. The fastener posts 2418 align with fastener apertures 2424 andaccept the fasteners 2470 securing the front cover 2410 to the backcover 2420.

Also shown in FIGS. 24A–B, the terminal set 2430 has power clips 2432,fixed wire terminals 2434 and breakaways 2438. The power clips 2432provide the conductor portion of the structured sockets 2412 and areconfigured to physically and electrically connect with module prongs ina manner as described with respect to FIG. 21, above. The fixed wireterminals 2434 electrically and mechanically connect a striped end ofthe fixed wires 2350 (FIGS. 23A–B) to the terminal set 2430. Thebreakaways 2438 are removable to selectively isolate individual powerclips 2432.

Further shown in FIGS. 24A–B, the mounting bracket 2450 is adapted to achannel extending lengthwise along the front cover 2410 andcorresponding support structure extending lengthwise along the backcover 2420. The mounting bracket 2450 has box mounts 2452, module mounts2454, a ground clip aperture 2456 and a ground terminal 2458. The boxmounts 2452 accept fasteners (not shown) to secure the bracket to anelectrical box (not shown). The module mounts 2454 accept fasteners (notshown) to secure a functional module (not shown) to the wiring module2300. The ground clip aperture 2456 is adapted to the ground clip 2460,which connects a functional module ground bar electrically andmechanically to the bracket 2450. The bracket has an integrated rivetfor securing the ground clip 2460 within the aperture 2456. The groundterminal 2458 electrically and mechanically connects a striped end of aground one of the fixed wires 2350 (FIGS. 23A–B) to the bracket 2450.

Additionally shown in FIGS. 24A–B, the back cover 2420 has wireapertures 2422, fastener apertures 2424 and a breakaway aperture 2426.The wire apertures 2422 are adapted to the fixed wires 2350 (FIGS.23A–B) so as to provide a seal around and strain relief for the fixedwires and access to the terminal set 2430 and ground terminal 2458. Thefastener apertures 2424 accept that portion of the fasteners 2470 thatthread into or are otherwise secured to the fastener posts 2418. Thebreakaway aperture 2426 allows user access to the breakaways 2438 withinan assembled wiring module 2300.

Electrical Box Cover

FIGS. 25A–B illustrate an electrical box cover 2500 having a generallyplanar cover plate 2510, clamps 2520, catches 2530, trusses 2540 andmarkers 2550. The cover plate 2510 has a front side 2501 and a back side2502. The clamps 2520 are located, one each, generally centered on thetop and bottom of the cover plate 2510 and extend generallyperpendicularly from the back side 2502. The catches 2530 are apertures,one for each catch 2530, that are generally centered on the catches 2520and extending along the juncture between the catches 2530 and the coverplate 2510. The trusses 2540 are protrusions on the cover plate 2540that extend substantially along the length of the front side 2501,providing structural support to resist bending of the cover plate 2510.The markers 2550 are generally round protrusions on the front side 2501of the cover plate 2540 located, one each, proximate the top and bottomof the cover plate 2540.

FIGS. 26A–B illustrate an electrical box 2600 that is covered anduncovered, respectively, by a box cover 2500, as described with respectto FIGS. 25A–B, above. The box cover 2500 removably mounts over theelectrical box open face 2601 so as to prevent material such as plasterand paint from fouling the wiring module 1600 during the makeup phase ofconstruction. Advantageously, the box cover 2500 mounts generally flushwith the electrical box open face 2601 and, hence, generally flush withinstalled drywall so as not to interfere with drywall constructionduring the makeup phase. Drywall, once loosely positioned, can bepressed against the box cover 2500. In doing so, the markers 2550 dimplethe drywall, advantageously marking the location of the electrical box2600 so that drywall cutouts can be accurately made to accommodate theelectrical box 2600.

As shown in FIGS. 26A–B, the box cover 2500 is installed on the boxmounts 1920 of a wiring module 1600 mounted within the electrical box2600. In particular, the clamps 2520 flex somewhat to slide over the boxmounts 1920 until the box mounts 1920 insert into corresponding catches2530. The box cover 2500 can be easily removed by flexing the clamps2520 so that a box mount 1920 clears a corresponding catch 2530.

FIG. 25 illustrate a 2-gang electrical box 2500 with overlapping boxcovers 2500. The box covers 2500 are configured so that a first portion2591 of one cover overlaps a second portion 2592 of another cover so asto prevent drywall related material from entering between the covers2500 and fouling the electrical box 2700 interior.

Terminal Shield

FIGS. 28A–B illustrate a terminal-block wiring module 1600 having aterminal shield 2900 installed on a wiring side 1602 using fasteners1909. The terminal shield 2900 advantageously prevents bare copperground wires (not shown), which typically are connected between theground terminal 1907 (FIG. 17A) and an electrical box (not shown), frominadvertently protruding through the back cover 2200 (FIG. 17A) andshort circuiting the terminal set 2100 (FIG. 17A).

FIGS. 29A–B illustrate a terminal shield 2900 having a front side 2901,a back side 2902 and a spine 2905. Mounting ears 2910 extend from bothends of the spine 2905, and shield wings 2920 extend from both sides ofthe spine 2905. Breakaway guards 2930 extend from a central portion ofeach shield wing 2920. A V-shaped hinge 2935 extending across a portionof each breakaway guard 2930 allows the breakaway guards 2930 to flexsomewhat to gain access for removal of one or both of the breakaways2116 (FIG. 16F), as described with respect to FIGS. 16G–H, above.Mounting apertures 2940 are defined in the mounting ears 2910, wireapertures 2950 are defined in the shield wings 2920, and a bracketaperture 2960 is defined in a central portion of the spine 2905.

As shown in FIGS. 29A–B, the terminal shield 2900 is installed with theback side 2902 proximate the wiring module 1600 (FIG. 28A) and the frontside 2901 distal the wiring module 1600 (FIG. 28A). In particular, thespine 2905 fits against the bracket 1900 and the bracket aperture 2960accommodates protrusions due to the ground clip 1902 (FIG. 17A) or itsassociated fastener. The mounting apertures 2940 accept the fasteners1909 (FIG. 28A), which also secure together the wiring module 1600 (FIG.28A). The shield wings 2920 cover exposed portions of the terminal set2100 (FIG. 17A), and the wire apertures 2950 accommodate wire ends thatare connected to the terminal set 2100 (FIG. 17A).

Dimmer Switch Module

FIGS. 30A–B illustrate a dimmer switch module 3000 having a powercontrol 3200 and a dimmer control 3500 on a front side 3001 and shieldedplugs 3010 and a key bar 3820 on a back side 3002. The power control3200 actuates an internal switch that routes electrical power betweenthe shielded plugs 3010 to turn on and off a light, for example. Thedimmer control 3500 actuates an internal potentiometer that controls thecurrent between the shielded plugs 3010 to adjust a light's intensity,for example. The shielded plugs 3010 physically and electrically connectthe dimmer switch module 3000 to a wiring module 1600 (FIGS. 16A–B). Thekey bar 3820 provides a non-conducting structure that assists inorienting the dimmer switch module 3000 relative to a wiring module.

FIG. 31 further illustrates the dimmer switch module 3000 having a powercontrol 3200, a front cover 3300, a spring 3400, a dimmer control 3500,a heat sink 3600, a dimmer circuit board 3700 and a back cover 3800.Advantageously, the heat sink 3600 is partially enclosed between thefront and back covers 3300, 3800 with fins 3620 extending outside thecovers 3300, 3800 so as to provide a substantial heat dissipatingsurface area outside of the module 3000. The module heat sink 3600 isthermally coupled to a triac 3710 mounted on the circuit board 3700 soas to dissipate heat generated by the triac 3710.

As shown in FIG. 31, the covers 3300, 3800 snap together with a latchand catch assembly so as to form a module housing that retains the heatsink 3600, circuit board 3700 and dimmer control 3500. The power control3200 and the dimmer control 3500 are slidably retained by the frontcover 3300. The power control 3200 is movable between an on position andan off position and remains in its manually set position under tensionfrom the spring 3400. The dimmer control 3500 engages the circuit board3700 and the front cover 3300 and is movable over a continuum of currentsetting positions ranging from a low current position to a high currentposition. The dimmer circuit board 3700 routes electrical power from awiring module as determined by the power control 3200 and controls theamount of electrical current and power as determined by the dimmercontrol 3500. The circuit board 3700 is secured to the back cover 3800with fasteners 3020.

The power control 3200, front cover 3300, spring 3400 and dimmer control3500 are described in detail with respect to FIGS. 32–35, below. Theheat sink 3600, dimmer circuit board 3700 and the back cover 3800 aredescribed in detail with respect to FIGS. 36–38, below. The dimmerswitch circuit is described with respect to FIG. 39, below.

FIGS. 32A–B illustrate a power control 3200 that is generallyrectangular having a front side 3201 and a back side 3202. The frontside 3201 has a finger grip 3210 for manually sliding the power control3200 between an on position and an off position. The back side 3202 haslatches 3220, a lever 3230 and a knob 3240 extending generally normal tothe plane of the back side 3202. The latches 3220 are adapted to passthrough front cover catch slots 3314 (FIGS. 33A–B), seating the powercontrol 3200 into the front cover 3300 (FIGS. 33A–B). The lever 3230inserts through a front cover power control slot 3312 (FIGS. 33A–B) anda heat sink slot 3640 (FIGS. 36A–B) so as to actuate a circuit boardswitch 3720 (FIGS. 37A–C). In particular, the lever 3230 has a verticalface 3232 and an angled face 3234 at its tip. The vertical face 3232actuates the switch 3720 (FIGS. 37A, C) to an off position and theangled face 3234 actuates the switch 3720 (FIGS. 37A, C) to an onposition. The knob 3240 presses against the spring 3400 (FIGS. 34A–B) soas to provide tension to the power control 3200 and to define on and offpositions.

FIGS. 33A–B illustrate a front cover 3300 having an outside face 3301,an inside face 3302, a power control cavity 3310, a dimmer lever slot3320, side latches 3330 and posts 3340. Located on the outside face3301, the power control cavity 3310 is configured for the power control3200 (FIGS. 32A–B). Within the power control cavity 3310 are a powerlever slot 3312, catch slots 3314 and spring holders 3316. The powerlever slot 3312 allows the power control lever 3230 (FIGS. 32A–B) topass through the front cover 3300 to the circuit board 3700 (FIGS.37A–C). The catch slots 3314 retain the power control latches 3220(FIGS. 32A–B), as described above. The spring holders 3316 areconfigured to retain the spring 3400 (FIGS. 34A–B) within the powercontrol cavity 3310. Also located on the outside face 3301, the dimmerlever slot 3320 allows a dimmer lever 3510 (FIGS. 35A–B) to protrudethrough the front cover 3300 so that the dimmer control 3500 (FIGS.35A–B) can be manually positioned. The side latches 3330 insert intoback cover side catches 3830 (FIGS. 38A–B) so as to secure together thefront cover 3300 and the back cover 3800 to form a housing, as describedabove.

FIGS. 34A–B illustrate a spring 3400, which provides tension and aposition retaining mechanism for the power control 3200 (FIGS. 32A–B).The spring 3400 has a curved middle 3410, flat surfaces 3420 extendingfrom the middle 3410 and folded ends 3430. The middle 3410 pushesagainst the power control knob 3240 (FIGS. 32A–B) forcing the knob 3240(FIGS. 32A–B) to one of the flat surfaces 3420 so as to retain the powercontrol 3200 (FIGS. 32A–B) in either an on or off position untilmanually actuated. The ends 3430 extend perpendicularly to the flatsurfaces 3420 so as to grasp the spring holders 3316 (FIGS. 33A–B).

FIGS. 35A–B illustrate a dimmer control 3500 having a dimmer lever 3510,a clip 3520 and guides 3530. The dimmer lever 3510 extendsperpendicularly from the guides 3530 and protrudes through the dimmerlever slot 3320 (FIGS. 33A–B) so as to be accessible for manualactuation. The clip 3520 defines a generally centered clip aperture 3522that fits over and retains a potentiometer control 3732 (FIGS. 37A–C).The guides 3530 are supported by the front cover inside face 3302 (FIGS.33A–B) and extend beyond the ends of the dimmer control slot 3320 (FIGS.33A–B). As the dimmer control 3500 is slidably actuated, thepotentiometer control 3732 (FIGS. 37A–C) is slideably actuated so as toadjust the resistance of the potentiometer 3730 (FIGS. 37A–C), dimming alight or otherwise changing current through the dimmer module 3000, asdescribed below.

FIGS. 36A–B illustrate a heat sink 3600 having a body 3610, fins 3620extending generally perpendicularly from and folded back toward the body3610, attachment ears 3630, a slot 3640, a potentiometer aperture 3650,latch apertures 3660 and thru holes 3670. The attachment ears 3630define apertures 3632 that accept fasteners so that the dimmer switchmodule 3000 (FIGS. 30A–B) can be secured to a wiring module. The slot3640 passes the power control lever 3230 (FIGS. 32A–B) as describedabove. The potentiometer aperture 3650 accommodates the potentiometer3730 (FIGS. 37A–C). The latch apertures 3660 pass the front coverlatches 3330 (FIGS. 33A–B) to the back cover catches 3830 (FIGS. 38A–B).The thru holes 3670 allow tool access to the circuit board fasteners3020 (FIG. 31).

FIGS. 37A–C illustrate a circuit board 3700 having a printed circuitsubstrate 3705 with mounted components 3710–3740 on a front side 3701and prongs 3750 extending from a back side 3702. The major mountedcomponents are a triac 3710, a switch 3720, a potentiometer 3730 and acoil 3740, described below. The triac 3710 is secured to the heat sink,as shown in FIG. 31, above. The prongs 3750 form the conductive portionsof the shielded plugs 3010 (FIGS. 30A–B).

FIGS. 38A–B illustrate a back cover 3800 having an inside face 3802, anoutside face 3801, shields 3810, a key bar 3820, side catches 3830 andmounting posts 3840. As shown in FIG. 38B on the outside face 3801, theshields 3810 provide the shield portion of the shielded plugs 3010(FIGS. 30A–B). In particular, the shields 3810 completely surround allsides of the prongs 3750 (FIGS. 37A–C) so that the prongs 3750 (FIGS.37A-C) are not exposed while the dimmer switch module 3000 is engagedwith a wiring module, even when the dimmer switch module 3000 ispartially separated from a wiring module. The key bar 3820 is configuredto insert into a wiring module ground socket so as to orient the dimmerswitch module 3000. The side catches 3830 accept and engage the sidelatches 3330 (FIGS. 33A–B) so as to secure the front cover 3300 to theback cover 3800. As shown in FIG. 38A on the inside face 3802, themounting posts 3840 define apertures that accommodate fasteners 3020(FIG. 31) that attach the circuit board 3700 (FIG. 37A–C) to the backcover 3800.

FIG. 39 illustrates a dimmer circuit 3900, such as implemented on thecircuit board 3700, described above. The dimmer circuit 3900 has themajor components identified with respect to FIGS. 37A–C including atriac 3710, on/off switch 3720, potentiometer 3730 and coil 3740. Thetriac 3710 is a power control element for the circuit 3700. The switch3720 enables and disables the circuit 3700. The coil 3740 and a first RCfilter 3910 suppress RF (radio frequency) electrical noise. A currentlimiting resistor 3920 protects the potentiometer 3730 in the event of ashort circuit. A second RC filter 3940 smoothes the current input to adiac 3930. In operation, the triac 3710 is initially nonconducting. Thepotentiometer 3730 variably sets the trigger point of a diac 3930 withinan AC power cycle. In particular, the capacitor 3950 is charged throughthe potentiometer 3730 until the trigger level of the diac 3930 isreached and it fires. This causes the triac 3710 to be conductive sothat current flows between the prongs 3750. The triac 3710 will remainin a conductive mode until the current flowing between the prongs 3750is lower than the triac hold current at the end of a half period of theAC power cycle.

Other Functional Modules

Although described above with respect to outlet and switch modules, theelectrical distribution system may operate in conjunction with a varietyof functional modules providing various electrical functions, such assecurity modules, data transfer modules, computing modules, homeentertainment modules and intelligent home product modules to name afew. For example, a security module may incorporate a video camera ormotion sensor. A data transfer module may incorporate data storagedevices, wireless transceivers or AC power line transceivers. Acomputing module may incorporate a microprocessor, a data entry ordisplay device, for example. A home entertainment module may work inconjunction with speakers, LCD panels or plasma TVs. A home productmodule, for instance, may incorporate a microcontroller and a wirelessor an AC power line transceiver for appliance control.

A functional module has been disclosed in detail in connection withvarious embodiments. These embodiments are disclosed by way of examplesonly and are not to limit the scope of the claims that follow. One ofordinary skill in the art will appreciate many variations andmodifications.

1. A functional module comprising: a housing having a front cover havinga front face defining an electrical distribution function and a backcover having a back face defining a plurality of shielded plugs; aplurality of latches and a corresponding plurality of catches disposedon each side around the periphery of said faces so as to hold togethersaid covers; and a contact set at least partially enclosed by thehousing, wherein said front face defines an electrical distributionfunction, wherein said back face defines a plurality of shielded plugs,wherein said contact set is adapted to communicate electrical power viasaid shielded plugs for said electrical distribution function, andwherein each of the shielded plugs comprise: a prong; a wall disposedaround the prong having a generally rectangular shape.
 2. The functionalmodule according to claim 1 wherein the contact set comprises: a buss; aground clip; and a ground bar, wherein each of said buss, ground clipand ground bar are separately stamped and folded parts that are fixedlyattached together.
 3. A functional module adapted to removably connectto a wiring module mounted within an electrical box and connected to apower cable, said functional module comprising; a housing providing anelectrical distribution function on a first face and a plurality ofprongs extending from the opposite second face; a around contact set atleast partially enclosed within the housing; and a plurality of shieldsdisposed with a generally rectangular shape around the prongs andextending from the second face substantially the length of the prongs,wherein the ground contact set comprises a plurality of separatelystamped and folded parts that are fixedly attached together, wherein theground contact set provides a plurality of ground clips for theelectrical distribution function and a ground bar adapted to provide aground path between the wiring module and the electrical distributionfunction, wherein the housing comprises a first cover defining the firstface and a second cover defining the second face, and wherein the coversare latched together on each of a plurality of opposite sides disposedaround the periphery of the faces.
 4. A functional module comprising: afront face providing access to an electrical distribution function; aback face opposite the front face; a power contact set including aplurality of prongs extending from the back face; and a plurality ofshields disposed in a generally rectangular cross-section around theprongs and extending from the back face about the length of the prongsso as to form in conjunction with the prongs a plurality of shieldplugs, wherein the shielded plugs are configured to removably andelectrically connect to a wiring module so as to provide communicationsbetween the electrical distribution function and an electrical powersource via the wiring module.
 5. The functional module according toclaim 4 wherein the electrical distribution function comprises aplurality of electrical outlets, the functional module furthercomprising a ground contact set configured to provide a ground pathbetween the outlets and the wiring module, the ground contact setcomprising: a buss; and a first ground contact and a second groundcontact riveted to the buss, wherein the first ground contact has afirst ground clip disposed proximate a first one of the outlets and aground bar extending from the back face, the ground bar configured toremovably insert into a corresponding ground connector on the wiringmodule, and wherein the second ground contact has a second ground clipdisposed proximate a first one of the outlets.
 6. The functional moduleaccording to claim 5 further comprising: a front cover defining thefront face and a back cover defining the back face, wherein the coversare latched together on each of a plurality of opposite sides disposedaround the periphery of the faces so as to at least partially enclosethe power contact set and the ground contact set.